Butted sensor array with supplemental chip in abutment region

ABSTRACT

The present invention relates to photosensitive chips for creating electrical signals from an original image, as would be found for example in a digital scanner, copier, facsimile machine, or other document generating or reproducing device. More specifically, the present invention relates to preferably providing a supplemental chip in each abutment region to enhance image quality.

FIELD OF THE INVENTION

[0001] The present invention relates to photosensitive chips for creating electrical signals from an original image, as would be found for example in a digital scanner, copier, facsimile machine, or other document generating or reproducing device. More specifically, the present invention relates to preferably providing a supplemental photosensitive chips in abutment regions to enhance image quality.

BACKGROUND OF THE INVENTION

[0002] Image sensor arrays typically comprise a linear array of photosensors which raster scan an image bearing document and convert the microscopic image areas viewed by each photosensor to image signal charges. Each photosensor collects light from a corresponding photosite. Following an integration period, the image signal charges are amplified and transferred as an analog video signal to a common output line or bus through successively actuated multiplexing transistors. One example of such an array is a charged-coupled device (CCD).

[0003] For high-performance image sensor arrays, a preferred design includes an array of photosites of a width comparable to the width of a page being scanned, to permit one-to-one imaging generally without the use of reductive optics. In order to provide such a “full-width” array, however, relatively large silicon structures must be used to define the large number of photosites. A preferred technique to create such a large array is to align several butted silicon chips, each chip defining a small linear array thereon.

[0004] The silicon chips which are butted to form a single full-width array are typically created by first creating the circuitry for a plurality of individual chips on a single silicon wafer. The silicon wafer is then cut or “diced,” around the circuit areas to yield discrete chips. Typically, the technique for dicing the chips includes a combination of chemical etching and mechanical sawing. On each chip, photosites are spaced from one end of a chip to the other; the length of each diced chip from one end of the array thereon to the other requires precision dicing. It would be desirable to dice each individual chip with a precise dimension along a linear array of photosites, so that, when a series of chips are butted end-to-end to form a single page-width linear array, there is a minimum disruption of spacing from an end photosite on one chip to a neighboring photosite at the end of a neighboring chip. This minimum disruption of spacing is referred to as an abutment region. Ideally, the pitch, across an entire full-width linear array should be consistent regardless of the configuration of silicon chips forming the array. Pitch is the distance between the center points of two adjacent photosites.

[0005] Preferably, the full-width array extends the entire length of a document, such as eleven inches. Usually, the full-width array is used to scan line by line across the width of a document with the document being moved or stepped lengthwise in synchronism therewith. A typical architecture for such a sensor array is given, for example, in U.S. Pat. No. 5,473,513. When the original document moves past the full-width array, each of the photosites receives reflected light and the corresponding photosensors convert reflected light from the original image into electrical signals. The motion of the original image perpendicular to the linear array causes a sequence of signals to be output from each photosensor, which can be converted into digital data.

[0006] With the gradual introduction of color-capable products into the office equipment market, it has become desirable to provide scanning systems which are capable of converting light from full-color images into separate trains of image signals, each train representing one primary color. In order to obtain the separate signals relating to color separations in a full-color image, one technique is to provide on each semiconductor chip multiple parallel linear arrays of photosites with corresponding photosensors, each of the parallel arrays being sensitive to one primary color. Typically, this arrangement can be achieved by providing multiple linear arrays of photosites which are physically identical except for a translucent primary-color overlay over photosites for that linear array. In other words, the linear array which is supposed to be sensitive to red light only will have a translucent red layer placed on the photosites thereof, and such would be the case for a blue-sensitive array and a green-sensitive array. Although it is preferable to use three linear arrays, any number of linear arrays can be used. As the chips are exposed to an original full-color image, only those portions of the image, which correspond to particular primary colors, will reach the photosensors assigned to the primary color. Thus, the photosite determines what portions of the image will reach the photosensors.

[0007] The most common substances for providing these translucent filter layers over the photosites is polyimide or acrylic. For example, polyimide is typically applied in liquid form to a batch of photosensitive chips while the chips are still in undiced, wafer form. After the polyimide liquid is applied to the wafer, the wafer is centrifuged to provide an even layer of a particular polyimide. In order to obtain the polyimide having the desired primary-color-filtering properties, it is well known to dope the polyimide with either a pigment or dye of the desired color, and these dopants are readily commercially available. When it is desired to place different kinds of color filters on a single chip, a typical technique is to first apply an even layer of polyimide over the entire main surface of the chip (while the chip is still part of the wafer) and then remove the unnecessary parts of the filter by photo-etching or another well known technique. Typically, the entire filter layer placed over the chip is removed except for those areas over the desired set of photosites. Acrylic is applied to the wafer in a similar manner.

[0008] In the prior art, there was a problem in that the edge photosites of the chips may not capture all of the reflected light in the abutment region. Therefore, the corresponding photosensors would not convert all of the reflected light from the original image into electrical signals. Although U.S. patent application Ser. No. 09/039,523, U.S. patent application Ser. No. 09/282,317, U.S. patent application Ser. No. 09/211,761 and U.S. patent application Ser. No. 09/211,765, have provided alternative techniques to improve image quality, there is a continuing need to enhance image quality by capturing as much of the reflected light from the original image as possible, so that the corresponding photosensors can accurately convert the original image into electrical signals for conversion to digital data to enhance image quality.

SUMMARY OF THE INVENTION

[0009] An assembly including a substrate; a plurality of butted photosensitive chips mounted to the substrate, wherein each photosensitive chip has an edge photosite and wherein an abutment region is formed between the edge photosites of butted photosensitive chips; and at least one photosensitive chip mounted to the substrate and butted to two photosensitive chips along the abutment region. Each photosensitive chip has a plurality of edge photosites. Each of the photosensitive chips defines a plurality of photosites evenly spaced thereon, the photosites being positioned to form a linear array on the substrate. Each of the supplemental photosensitive chips defines a plurality of photosites evenly spaced thereon.

[0010] Alternatively, each of the photosensitive chips defines a plurality of photosites evenly spaced thereon, the photosites being positioned to form multiple parallel linear arrays on the substrate. Each linear array is covered by a different translucent filter. Each of the supplemental photosensitive chips defines a plurality of photosites evenly spaced thereon, the photosites being positioned and covered with translucent filter materials to correspond with multiple parallel linear arrays formed by the photosensitive chips.

[0011] A document generating device including a raster input scanner scanning documents to generate digital image signals, the raster input scanner including a photosensitive chip assembly having photosensitive chips and supplemental photosensitive chips mounted to a substrate; a photoreceptor; a controller; a raster output scanner, being directed by the controller to expose the photoreceptor to create an electrostatic latent image based on the digital image signals received from the raster input scanner; a developer developing the latent image; a transfer unit transferring the developed image to a support material; and a fuser unit permanently affixing the developed image on the support material. The photoreceptor can be a photoconductive belt. The document generating device may further include a plurality of raster output scanners directed by the controller to expose the photoreceptor to create the latent image; and a plurality of developers, each developer applying a different color to develop the latent image.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a perspective view of a base substrate having a plurality of butted chips mounted thereon to form a photosensitive chip assembly;

[0013]FIG. 2 is a plan view showing an example of a photosensitive chip used in the present invention;

[0014]FIG. 3 is a perspective view showing an example of two photosensitive chips used in the present invention;

[0015]FIG. 4 is a perspective view of a semiconductor wafer relevant to the present invention;

[0016]FIG. 5 is a blow up of two butted photosensitive chips and a supplemental photosensitive chip butted to the two photosensitive chips forming a photosensitive chip assembly in accordance with the present invention;

[0017]FIG. 6 is a partial schematic elevational view of a first example of a digital copier, which can employ the photosensitive chip assembly of the present invention; and

[0018]FIG. 7 is a partial schematic elevational view of a second example of a digital copier, which can employ the photosensitive chip assembly of the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0019]FIG. 1 shows a plurality of photosensitive chips 10 mounted and butted on a substrate 20 from end to end to form an effective collinear array of photosites, which extends across a page image being scanned for a scanner, copier, facsimile machine or other document reading or generating device. Thus, the plurality of chips 10 mounted to substrate 20 forms a full-width array. Generally, each individual photosite receives reflected light and each corresponding photosensor is adapted to output a charge or voltage signal indicative of the intensity of light of a certain type received through the photosite; various structures, such as transfer circuits, or charged coupled devices, are known in the art for processing signal output by the various photosites. A plurality of supplemental photosensitive chips 11 are also mounted on a substrate 20 to augment the full-width array. Preferably, each supplemental photosensitive chip 11 is butted against two photosensitive chips 10 in the abutment region as shown in FIG. 1. The photosensitive chips 10 and supplemental photosensitive chips 11 mounted to substrate 20 form a photosensitive chip assembly. Preferably, the number of supplemental photosensitive chips 11 (M) is one less than the number of photosensitive chips 10 (N), where M and N are whole numbers.

[0020]FIG. 2 is a plan view showing one of these photosensitive chips 10 relevant to the claimed invention. The chip 10 is generally made of a semiconductor substrate, as is known in the art, in which circuitry and other elements are formed, such as by photolithographic etching. A few of the most relevant structures are one or more linear arrays of photosites 12, each of which forms the photosensitive surface of circuitry within the chip 10, and a set of bonding pads 14. The photosites 12 are typically arranged in a linear array along one main dimension of the chip 10, with each photosite 12 along the array corresponding to one pixel in an image signal. As will be described in detail below, the photosites 12 are preferably for sensing the three primary colors, blue, green and red. Photosites, which sense blue, green and red, are referred to as photosites 12B, 12G and 12R. Each photosite is associated with a corresponding photosensor. Preferably, the photosites are uniformly spaced to provide a uniform pitch, which enhances digital signal processing. Pitch is the distance between the center of one photosite and the center of an adjacent photosite. Preferably, there are three parallel linear arrays 16 a, 16 b, and 16 c for the three primary colors. However, any number of linear arrays may be utilized. For example, only one linear array could be placed on the chip 10 for use in a monochrome scanner, copier, printer, etc.

[0021] The bonding pads 14 are distinct surfaces on the main surface of the chip 10, and are intended to accept wire bonds attached thereto. The bonding pads 14 thus serve as the electronic interface between the chip 10 and any external circuitry. The circuitry for obtaining signals related to light directed to the photosites 12, and for unloading image data from the chip 10 is generally indicated as 15. The circuitry 15 is generally deposited between the linear array of photosites 12 and a linear array of bonding pads 14.

[0022] Chips 10 are typically formed in batches on semiconductor wafers, which are subsequently cleaved, or “diced,” to create individual chips. Typically, the semiconductor wafers are made of silicon. As is known in the art, photolithographically etched V-grooves 18 define precisely the intended boundaries of a particular chip 10 for dicing as shown in the perspective view of two adjacent chips 10 in FIG. 3. Thus, all of the photosites 12, bonding pads 14 and circuitry 15 for relatively large number of chips 10 are etched simultaneously onto a single semiconductor wafer. The region between the V-grooves 18 is called the tab region. The photosites 12 adjacent to each V-groove in FIG. 3 (adjacent to the edge as shown in FIG. 2) are referred to as an edge or outer photosites. The other photosites 12 are referred to as inner photosites.

[0023]FIG. 4 shows a typical semiconductor wafer 30, in isolation, wherein a relatively large number of chips 10 are created in the wafer 30 prior to dicing thereof. Each chip 10 has a distinct chip area within the main surface of the wafer 30. The phrase “chip area” refers to a defined area within the main surface of the wafer 30 which is intended to comprise a discrete chip 10 after the dicing step, when individual chips 10 (FIG. 2) are separated from the rest of the wafer 30.

[0024] Although the structure and manufacturing techniques of the photosensitive chip 10 have been discussed with reference to FIGS. 2 through 4, the same or similar techniques and structures may be used to provide the supplemental photosensitive chips 11.

[0025]FIG. 5 shows a blow up of two butted photosensitive chips 10 and a supplemental photosensitive chip 11 butted to the two photosensitive chips 10 along the abutment region in FIG. 1. As discussed above, all of these chips are mounted to a substrate 20 forming a photosensitive chip assembly in accordance with the present invention. As shown in FIG. 5, a few of the most relevant structures are one or more linear arrays of photosites 12, each of which forms the photosensitive surface of circuitry within the supplemental photosensitive chip 10, and a set of bonding pads 14. The photosites 12 are typically arranged in a linear array along one main dimension of the chip 10, with each photosite 12 along the array corresponding to one pixel in an image signal. The photosites 12 are preferably for sensing the three primary colors, blue, green and red. Photosites 12, which sense blue, green and red, are referred to as photosites 12B, 12G and 12R. Each photosite is associated with a corresponding photosensor. Preferably, the photosites are uniformly spaced to provide a uniform pitch, which enhances digital signal processing. Pitch is the distance between the center of one photosite and the center of an adjacent photosite. Preferably, there are three parallel linear arrays 16 a, 16 b, and 16 c for the three primary colors. However, any number of linear arrays may be utilized. For example, only one linear array could be placed on the supplemental photosensitive chip 11 for use in a monochrome scanner, copier, printer, etc.

[0026] The bonding pads 14 are distinct surfaces on the main surface of the supplemental photosensitive chip 11, and are intended to accept wire bonds attached thereto. The bonding pads 14 thus serve as the electronic interface between the supplemental photosensitive chip 11 and any external circuitry. The circuitry for obtaining signals related to light directed to the photosites 12, and for unloading image data from the supplemental photosensitive chip 11 is generally indicated as 15. The circuitry 15 is generally deposited between the linear array of photosites 12 and a linear array of bonding pads 14.

[0027] When the photosensitive chips 10 and supplemental photosensitive chips 11 are mounted to the substrate 20 to form the photosensitive chip assembly, the one or more linear arrays 16 of the supplemental photosensitive chips 11 are preferably two to twelve scan lines away from the one or more linear arrays 16 in the photosensitive chips 10. Preferably, the photosensitive chips 10 and supplemental photosensitive chips 11 are parallel to each other and in the same plane. Preferably, the number of photosites 12 in each linear array on the supplemental photosensitive chip 11 is three. However, there may be additional photosites 12 depending on the distance between the edge photosites 12 of the two photosensitive chips 10 (the length of the abutment region). This chip assembly has the advantage of potentially increasing the gap between the edges of photosensitive chips 10. This decreases the tolerance sensitivity of photosensitive chip placement.

[0028] When a document is scanned, the reflected light from an original image is received by the photosites of the photosensitive chip assembly, the corresponding photosensors provide electrical signals, which are converted into digital data. Before combining digital data generated by the supplemental photosensitive chips 11 with digital data generated by the photosensitive chips 10, digital data generated by the supplemental photosensitive chips 11 is preferably interpolated to minimize any data errors due to misalignment errors between the photosites 12 on the photosensitive chip 10 and the photosites 12 on the supplemental photosensitive chip 11. These misalignment errors are positional errors caused by misplacement of the chips 10 and 11.

[0029]FIG. 6 is a partial schematic view of an example of a digital imaging system, such as the digital imaging system of U.S. application Ser. No. 08/838,630, including a scanner, which can utilize the assembly of photosensitive chips 10 and supplemental photosensitive chips 11. It will be understood, however, that it is not intended to limit the invention to the embodiment disclosed. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

[0030] An original document is positioned in a document handler 227 on a raster-input scanner (RIS) indicated generally by reference numeral 228. The RIS 228 contains document illumination lamps, optics, a mechanical scanning device and a photosensitive chip assembly of the present invention. The photosensitive chips 10 and supplemental photosensitive chips 11 may include a linear array of photosites or multiple parallel linear arrays of photosites as described above. The RIS 228 captures the entire original document and converts it to a series of raster scan lines. This information is transmitted to an electronic subsystem (ESS) or controller 229 which controls a raster output scanner (ROS) 230.

[0031] The digital imaging system employs a photoconductive belt 210. Preferably, the photoconductive belt 210 is made from a photoconductive material coated on a ground layer, which, in turn, is coated on an anti-curl backing layer. Belt 210 moves in the direction of arrow 213 to advance successive portions sequentially through the various processing stations deposited about the path of movement thereof. Belt 210 is entrained about stripping roller 214, tensioning roller 220 and drive roller 216. As roller 216 rotates, it advances belt 210 in the direction of arrow 213.

[0032] Initially, a portion of the photoconductive surface passes through charging station A. At charging station A, a corona generating device indicated generally by the reference numeral 222 charges the photoconductive belt 210 to a relatively high, substantially uniform potential.

[0033] At an exposure station B, a controller or electronic subsystem (ESS) 229 receives the image signals representing the desired output image and processes these signals to convert them to a continuous tone or grayscale rendition of the image which is transmitted to a modulated output generator, for example the raster output scanner (ROS), indicated generally by reference numeral 230. Preferably, ESS 229 is a self-contained, dedicated minicomputer. The image signals transmitted to ESS 229 may originate from a RIS 228 as described above or another type of scanner utilizing the photosensitive chips 10, thereby enabling the absorption to serve as a remotely located printer for one or more scanners. Alternatively, the printer may serve as a dedicated printer for a high-speed computer or for one or more personal computers. The signals from ESS 229, corresponding to the continuous tone image desired to be reproduced by the printer, are transmitted to ROS 230. ROS 230 includes a laser with rotating polygon mirror blocks. The ROS 230 will expose the photoconductive belt 210 to record an electrostatic latent image thereon corresponding to the continuous tone image received from ESS 229. As an alternative, ROS 230 may employ a photosensitive array of light emitting diodes (LEDs) arranged to illuminate the charged portion of photoconductive belt 210 on a raster-by-raster basis.

[0034] After the electrostatic latent image has been recorded on photoconductive surface 212, belt 210 advances the latent image to a development station, C, where toner, in the form of liquid or dry particles, is electrostatically attracted to the latent image using commonly known techniques. The latent image attracts toner particles from the carrier granules forming a toner powder image thereon. As successive electrostatic latent images are developed, toner particles are depleted from the developer material. A toner particle dispenser, indicated generally by the reference numeral 244, dispenses toner particles into developer housing 246 of developer unit 238.

[0035] With continued reference to FIG. 6, after the electrostatic latent image is developed, the toner powder image present on belt 210 advances to transfer station D. A print sheet 248 is advanced to the transfer station, D, by a sheet feeding apparatus, 250. Preferably, sheet feeding apparatus 250 includes a nudger roll 251 which feeds the uppermost sheet of stack 254 to nip 255 formed by feed roll 252 and retard roll 253. Feed roll 252 rotates to advance the sheet from stack 254 into vertical transport 256. Vertical transport 256 directs the advancing sheet 248 of support material into the registration transport 290 and past image transfer station D to receive an image from photoreceptor belt 210 in a timed sequence so that the toner powder image formed thereon contacts the advancing sheet 248 at transfer station D. Transfer station D includes a corona-generating device 258, which sprays ions onto the backside of sheet 248. This attracts the toner powder image from photoconductive surface 212 to sheet 248. The sheet is then detached from the photoreceptor by corona generating device 259 which sprays oppositely charged ions onto the back side of sheet 248 to assist in removing the sheet from the photoreceptor. After transfer, sheet 248 continues to move in the direction of arrow 260 by way of belt transport 262, which advances sheet 248 to fusing station F.

[0036] Fusing station F includes a fuser assembly indicated generally by the reference numeral 270 which permanently affixes the transferred toner powder image to the copy sheet. Preferably, fuser assembly 270 includes a heated fuser roller 272 and a pressure roller 274 with the powder image on the copy sheet contacting fuser roller 272. The pressure roller 274 is loaded against the fuser roller 272 to provide the necessary pressure to fix the toner powder image to the copy sheet. The fuser roller 272 is internally heated by a quartz lamp (not shown). Release agent, stored in a reservoir (not shown), is pumped to a metering roll (not shown). A trim blade (not shown) trims off the excess release agent. The release agent transfers to a donor roll (not shown) and then to the fuser roll 272. Or alternatively, release agent is stored in a presoaked web (not shown) and applied to the fuser roll 272 by pressing the web against fuser roll 272 and advancing the web at a slow speed.

[0037] The sheet then passes through fuser 270 where the image is permanently fixed or fused to the sheet. After passing through fuser 270, a gate 280 either allows the sheet to move directly via output 284 to a finisher or stacker, or deflects the sheet into the duplex path 300, specifically, first into single sheet inverter 282 here. That is, if the sheet is either a simplex sheet, or a completed duplex sheet having both side one and side two images formed thereon, the sheet will be conveyed via gate 280 directly to output 284. However, if the sheet is being duplexed and is then only printed with a side one image, the gate 280 will be positioned to deflect that sheet into the inverter 282 and into the duplex loop path 300, where that sheet will be inverted and then fed to acceleration nip 202 and belt transports 310, for recirculation back through transfer station D and fuser 270 for receiving and permanently fixing the side two image to the backside of that duplex sheet, before it exits via exit path 284.

[0038] After the print sheet is separated from photoconductive surface 212 of belt 210, the residual toner/developer and paper fiber particles adhering to photoconductive surface 212 are removed therefrom at cleaning station E. Cleaning station E includes a rotatably mounted fibrous brush in contact with photoconductive surface 212 to disturb and remove paper fibers and a cleaning blade to remove the nontransferred toner particles. The blade may be configured in either a wiper or doctor position depending on the application. Subsequent to cleaning, a discharge lamp (not shown) floods photoconductive surface 212 with light to dissipate any residual electrostatic charge remaining thereon prior to the charging thereof for the next successive imaging cycle.

[0039] Controller or ESS 229 regulates the various printer functions. The controller or ESS 229 is preferably a programmable microprocessor, which controls all of the printer functions hereinbefore described. The controller or ESS 229 provides a comparison count of the copy sheets, the number of documents being recirculated, the number of copy sheets selected by the operator, time delays, jam corrections, etc. The control of all of the exemplary systems heretofore described may be accomplished by conventional control switch inputs from the printing machine consoles selected by the operator. Conventional sheet path sensors or switches may be utilized to keep track of the position of the document and the copy sheets.

[0040]FIG. 7 is a partial schematic view of another example of a digital imaging system, such as the digital imaging system of U.S. application Ser. No. 09/220,972, including a scanner, which can utilize the assembly of photosensitive chip 10 and supplemental photosensitive chips 11. The imaging system is used to produce color output in a single pass of a photoreceptor belt. It will be understood, however, that it is not intended to limit the invention to the embodiment disclosed. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims, including a multiple pass color process system, a single or multiple pass highlight color system and a black and white printing system.

[0041] In this embodiment, an original document can be positioned in a document handler 427 on a raster-input scanner (RIS) indicated generally by reference numeral 428. The RIS 428 contains document illumination lamps, optics, a mechanical scanning device and a photosensitive chip assembly of the present invention. The photosensitive chips 10 and supplemental photosensitive chips 11 may include a linear array of photosites 12 or multiple parallel linear arrays of photosites 12 as described above. The RIS 428 captures the entire original document and converts it to a series of raster scan lines. This information is transmitted to an electronic subsystem (ESS) or controller 490 which controls a raster output scanner (ROS) 424.

[0042] The printing machine uses a charge retentive surface in the form of an Active Matrix (AMAT) photoreceptor belt 410 supported for movement in the direction indicated by arrow 412, for advancing sequentially through the various xerographic process stations. The belt is entrained about a drive roller 414, tension rollers 416 and fixed roller 418 and the drive roller 414 is operatively connected to a drive motor 420 for effecting movement of the belt through the xerographic stations. A portion of belt 410 passes through charging station A where a corona generating device, indicated generally by the reference numeral 422, charges the photoconductive surface of photoreceptor belt 410 to a relatively high, substantially uniform, preferably negative potential.

[0043] Next, the charged portion of photoconductive surface is advanced through an imaging/exposure station B. At imaging/exposure station B, a controller, indicated generally by reference numeral 490, receives the image signals from raster input scanner 428 representing the desired output image and processes these signals to convert them to the various color separations of the image which is transmitted to a laser based output scanning device, which causes the charge retentive surface to be discharged in accordance with the output from the scanning device. Preferably the scanning device is a laser Raster Output Scanner (ROS) 424. Alternatively, the ROS 424 could be replaced by other xerographic exposure devices such as LED arrays.

[0044] The photoreceptor belt 410, which is initially charged to a voltage V₀, undergoes dark decay to a level equal to about −500 volts. When exposed at the exposure station B, it is discharged to a level equal to about −50 volts. Thus after exposure, the photoreceptor belt 410 contains a monopolar voltage profile of high and low voltages, the former corresponding to charged areas and the latter corresponding to discharged or background areas.

[0045] At a first development station C, developer structure, indicated generally by the reference numeral 432 utilizing a hybrid development system, the development roll, better known as the donor roll, is powered by two development fields (potentials across an air gap). One example of a hybrid development system is a hybrid jumping development (HJD) system. In a hybrid development system, the first field is the ac field which is used for toner cloud generation. In the HJD example, the ac field is an ac jumping field. In a hybrid development system, the second field is the dc development field which is used to control the amount of developed toner mass on the photoreceptor belt 410. The toner cloud causes charged toner particles 426 to be attracted to the electrostatic latent image. Appropriate developer biasing is accomplished via a power supply. This type of system is a noncontact type in which only toner particles (black, for example) are attracted to the latent image and there is no mechanical contact between the photoreceptor belt 410 and a toner delivery device to disturb a previously developed, but unfixed, image.

[0046] The developed but unfixed image is then transported past a second charging device 436 where the photoreceptor belt and previously developed toner image areas are recharged to a predetermined level.

[0047] A second exposure/imaging is performed by device 438 which comprises a laser based output structure is utilized for selectively discharging the photoreceptor belt 410 on toned areas and/or bare areas, pursuant to the image to be developed with the second color toner. At this point, the photoreceptor belt 410 contains toned and untoned areas at relatively high voltage levels and toned and untoned areas at relatively low voltage levels. These low voltage areas represent image areas which are developed using discharged area development (DAD). To this end, a negatively charged, developer material 440 comprising color toner is employed. The toner, which by way of example may be yellow, is contained in a developer housing structure 442 disposed at a second developer station D and is presented to the latent images on the photoreceptor belt 410 by way of a second developer system. A power supply (not shown) serves to electrically bias the developer structure to a level effective to develop the discharged image areas with negatively charged yellow toner particles 440.

[0048] The above procedure is repeated for a third image for a third suitable color toner such as magenta (station E) and for a fourth image and suitable color toner such as cyan (station F). The exposure control scheme described below may be utilized for these subsequent imaging steps. In this manner a full color composite toner image is developed on the photoreceptor belt 410.

[0049] To the extent to which some toner charge is totally neutralized, or the polarity reversed, thereby causing the composite image developed on the photoreceptor belt 410 to consist of both positive and negative toner, a negative pre-transfer dicorotron member 450 is provided to condition the toner for effective transfer to a substrate using positive corona discharge.

[0050] Subsequent to image development a sheet of support material 452 is moved into contact with the toner images at transfer station G. The sheet of support material 452 is advanced to transfer station G by a sheet feeding apparatus 500. The sheet of support material 452 is then brought into contact with photoconductive surface of photoreceptor belt 410 in a timed sequence so that the toner powder image developed thereon contacts the advancing sheet of support material 452 at transfer station G.

[0051] Transfer station G includes a transfer dicorotron 454 which sprays positive ions onto the backside of sheet 452. This attracts the negatively charged toner powder images from the photoreceptor belt 410 to sheet 452. A detack dicorotron 456 is provided for facilitating stripping of the sheets from the photoreceptor belt 410.

[0052] After transfer, the sheet of support material 452 continues to move, in the direction of arrow 458, onto a conveyor (not shown) which advances the sheet to fusing station H. Fusing station H includes a fuser assembly, indicated generally by the reference numeral 460, which permanently affixes the transferred powder image to sheet 452. Preferably, fuser assembly 460 comprises a heated fuser roller 462 and a backup or pressure roller 464. Sheet 452 passes between fuser roller 462 and backup roller 464 with the toner powder image contacting fuser roller 462. In this manner, the toner powder images are permanently affixed to sheet 452. After fusing, a chute, not shown, guides the advancing sheets 452 to a catch tray, stacker, finisher or other output device (not shown), for subsequent removal from the printing machine by the operator.

[0053] After the sheet of support material 452 is separated from photoconductive surface of photoreceptor belt 410, the residual toner particles carried by the non-image areas on the photoconductive surface are removed therefrom. These particles are removed at cleaning station I using a cleaning brush or plural brush structure contained in a housing 466. The cleaning brush 468 or brushes 468 are engaged after the composite toner image is transferred to a sheet. Once the photoreceptor belt 410 is cleaned the brushes 468 are retracted utilizing a device incorporating a clutch (not shown) so that the next imaging and development cycle can begin.

[0054] Controller 490 regulates the various printer functions. The controller 490 is preferably a programmable controller, which controls printer functions hereinbefore described. The controller 490 may provide a comparison count of the copy sheets, the number of documents being recirculated, the number of copy sheets selected by the operator, time delays, jam corrections, etc. The control of all of the exemplary systems heretofore described may be accomplished by conventional control switch inputs from the printing machine consoles selected by an operator. Conventional sheet path sensors or switches may be utilized to keep track of the position of the document and the copy sheets.

[0055] While FIGS. 6 and 7 shows one example of a digital document generating device incorporating an assembly of photosensitive chips 10 and supplemental photosensitive chips 11 it is understood that an assembly of photosensitive chips 10 and supplemental photosensitive chips 11 may be used in any digital scanning application of any digital document reading, generating or reproducing device.

[0056] While the invention has been described in detail with reference to specific and preferred embodiments, it will be appreciated that various modifications and variations will be apparent to the artisan. All such modifications and embodiments as may occur to one skilled in the art are intended to be within the scope of the appended claims. 

1. An assembly comprising: a substrate; a plurality of butted photosensitive chips mounted to the substrate, wherein each photosensitive chip has an edge photosite and wherein an abutment region is formed between the edge photosites of butted photosensitive chips; at least one photosensitive chip mounted to the substrate and butted to two photosensitive chips along the abutment region.
 2. The assembly as in claim 1, wherein each photosensitive chip has a plurality of edge photosites.
 3. The assembly as in claim 1, wherein each of the photosensitive chips defines a plurality of photosites evenly spaced thereon, the photosites being positioned to form a linear array on the substrate.
 4. The assembly as in claim 3, wherein each of the supplemental photosensitive chips defines a plurality of photosites evenly spaced thereon.
 5. The assembly as in claim 1, wherein each of the photosensitive chips defines a plurality of photosites evenly spaced thereon, the photosites being positioned to form multiple parallel linear arrays on the substrate.
 6. The assembly as in claim 5, wherein each linear array is covered by a different translucent filter.
 7. The assembly as in claim 5, wherein each of the supplemental photosensitive chips defines a plurality of photosites evenly spaced thereon, the photosites being positioned and covered with translucent filter materials to correspond with multiple parallel linear arrays formed by the photosensitive chips.
 8. A document generating device comprising: a raster input scanner scanning documents to generate digital image signals, the raster input scanner including a photosensitive chip assembly having photosensitive chips and supplemental photosensitive chips mounted to a substrate; a photoreceptor; a controller; a raster output scanner, being directed by the controller to expose the photoreceptor to create an electrostatic latent image based on the digital image signals received from the raster input scanner; a developer developing the latent image; a transfer unit transferring the developed image to a support material; and a fuser unit permanently affixing the developed image on the support material.
 9. The document generating device as in claim 8, wherein the photoreceptor is a photoconductive belt.
 10. The document generating device as in claim 8, further comprising: a plurality of raster output scanners directed by the controller to expose the photoreceptor to create the latent image; and a plurality of developers, each developer applying a different color to develop the latent image.
 11. The document generating device as in claim 10, wherein the photoreceptor is a photoconductive belt. 